Method of making pile fabrics



March 25, 1952 F. P, GROAT METHOD OF MAKING FILE FABRICS Filed Dec. 28, 1949 IN V EN TOR. Wangzl 5 f Gro 0Z Patented Mar. 25, 1952 Francis. P.- .Groat,.'Bloomsbu 1- g,. 2a., assignonio A The, Magee Carpet Company,.Bloomsburg; Pa., acorporation 'of Pennsylvania Application December 28, 1949;1Serial No'."135,444

SClaims. (Cl. 139'T39) )1 .This :invention relates. to y pile fabrics and -methodaof making the same.

.Moreparticularly it relatesto loop pile fabrics .or.-.loop ,.and.tuft pile fabrics wherein some of the rows of loopshave loopsof different heights. 1

.Heretofore, loop pile fabrics havebeen woven by .using .a:.series of knob wires and two..or.more frames of pile yarns (selectively. :raised .overthe shanks ofhthe wires which are of uniform-height.

#When the. wires .arewithdrawn, the 10.01 8, there- --..on wi11- be raised tothe height of theknobwhich pulls, the... pile warps so that loops -in. -the. preceding .row formed from the same warps: will be .reduced%-in height anwamount equal to the increase inthe heightofthe. loops raised by the knob. By, this method. the high and low loops iarenformed by "action of .the knob wire .and. the last .loop .in .each longitudinal series of loops in a-.the..same1warp. will always bea high loop.

In..my. .prior applicationfiled February-2, 1949, :SerialNumber 74,143, now Patent N0. 2,532,903, grantedlDecember.5,.1950, Iv disclosed a pile fabricahd method of. weaving the samelwhereinta .combination of plain. and-knob .wireswith or vv'ithout cutting .wires are used to produce loop lpilelfabrics .or loopsand tuft pile fabrics, with -theflloops in. some .of. the .rows being of-.difl'erent heights. :..In that method a conventional knob wire. is. used and the height of. the knob corresponds to the height of the plain wireso that the row. .ofdoops formed on the .knob wire. will .be raised, when thewireis withdrawn, to the height ,...ofI.1the highest loops in-therow formed .by with- .tdrawal pf .the. plain .wire. In othernwords the withdrawal... of "they knob .wire will 1 reduceztthe heightbfgsome of the loops formed by the-plain wire. but in so doing theloops .onthe knob wires will beirfaised to... a uniform .height correspond- ...ingYtOQflthe. heightof .the highest loops in the 'rows of loopsof unequal height.

I'I It .is. an object .of the. present invention. to provides loop pilefabric. or loop and tuft pilefabric ii'ha'vingjltransverse rows, ofloops .of different I Height 1-; and intermediate rows "of loops. .of, .no .greaterheig'ht than jthelow loops, in the rowsof fidifferent' height loops.

:iAjfurther object of the invention resides in provlding azmethod of weaving a loop pilefabricor afilopp and tuft pile fabric having transverse rows off'loops of different heights wherein knob. and plfain'wires arranged in alternation are employed to'form rows of loops with all thehighyloops being'formedby the plain wire and with all the m ps formed by "the knob'wire being. no higher ifthanthe height of" those loops in the row of high rows of loops on each of the wires.

loops reduced in-height by .the withdrawal-action of the-knob-wire.

-A' further object of theinvention resides ina :1 method of weaving a. loop vpile fabric or loop-and .tuftpile ,fabric'havingtwo or moreframesrofpile -warps selectively-raisedover plain andknob-rw-ires or plain,-.cutting andknob wires, with the plain and. knob-:wires arranged in alternation wherein v:the .knob wires when withdrawn will raiseithe .loops thereon to a height -no-greater than. the height 'ofythenother loops in thensamelongitudinal series formed from the same pile ewarp.

Other :objects and advantages' -of' the invention will be apparent during-the course of;.-;-the following description.

:In .thevaccompanying drawing forming: art

:of this specification and'inrwhich likenu-merals areemployed vtogdesignate like parts throughout :the same,

Fig. 1 is an exploded'viewin' perspective ojfia cutpand loop; pile fabric being wovenin accord- ..woven fabric,

Fig. 3 is'a fragmentarywarpwise sectionigshow- .ing a series of the wires inserteding-the fabric,

Fig g is a fragmentary warpwise sectionwofa loop pile fabric,.and,

*Fig. 5 is a fragmentary. warpwise section..of

'sthe fabricin Fig. i'showing the-wires insertedxin the. fabric.

In carrying out the method a conventional of the fabric isconventional and comprises upper and .lower'weft threads!) and 6 boundtogether by sets of. binder warps l and 8. Two or more frames of pile warps 93 and I0 extend betweenthe ,upperand lower .weftthreads, and stuffer. warps ll asshown in Fig. 2 are disposed beneath the pile warps;

v.Asthe pile warps are selectively raised by the jacquard mechanism the pile forming wires are successively inserted in the fabric. The wires used are'plain wires [2, cutting wires l3 and knob wires 14 inserted in the fabric in the order of a plain wire, a cutting wire, a knob wire, a cutting wire, etc. 1 After the insertion of'each wire the pile warps are restored to thev backing forming The'plain wires l2 and cutting wires 13 are of conventional construction with the height of the plain wire being less than the height of the shank of the cutting wire. The knob wire I4 is of special construction having a relative low shank with a raised portion or knob I5 on its end of less height than the height of the plain wire 12. The base of the raised portion or knob is flared. outwardly to provide a shoe l6 wider than the shank which serves to maintain the knob in an upright position when inserting and withdrawing the wires. Thus the loops formed on the cutting Wires will be higher than the loops formed on the plain wires and the loops formed on the plain wires will be higher than the height of the knob of the knob wires. After the desired number of wires have been inserted in the fabric they are succese sively withdrawn and re-inserted in the usual manner. Withdrawal of a plain wire produces a row of loops having a height corresponding to the height of the wire. When the cutting wire is withdrawn the loops formed thereon will be cut by the knife blade I! at the end of the wire forming rows of cut loops or tufts having a height greater than the height of the row of loops formed by the plain wire. When the knob wire is withdrawn the loops formed thereon are increased in height'as the loops pass over the knob l5 and if those loops are formed from the same pile warps as loops in the preceding row formed by the plain wire, the loops in the preceding row will 'be reduced in height a distance corresponding to the increase in height of the loops passing over the knob. The height of the knob I5 is less than the height of the plain wire I2 and when the loops on the knob wire are raised by the knob the amount of yarn borrowed from the loops in the preceding row is such that the loops in the preceding row will not be lowered to a height less than the increased height of the loops raised by the knob. Those pile warps which are raised over the plain wire and are buried beneath the knob wire will not be pulled by the withdrawal action of the knob wire so that the loops of these pile warps formed on the plain wire will remain high. Thus, the row of loops formed on the plain wire will after withdrawal of the wire and subsequent knob wire have high and low loops in the transverse row and the row of loops formed by the knob wire will be of uniform height of no greater height than the low loops in the rows of different height loops.

In Fig. 1 it will be seen that when the wires are woven in the fabric rows of loops of uniform height are formed on each of the wires, the loops l8 on the cutting wire being higher than the loops IS on the plain wires and the latter being higher than the loops 20 on the knob wires. After withdrawal of the wires, the row of loops [9 on the plain wire are converted into a row of high and low loops 2| by the action of the knob wire, the loops 18 are converted into tufts 22 by the action of the cutting wire and the loops 20 on the knob wire are increased in height to form a row of loops 23 having a height no greater than the low loops in row 2|.

Referring to Fig. 2 it will be seen no pile warp is raised in row one at the right. Warp pile I0 is raised in row two over a cutting wire which upon withdrawal forms a tuft 2A. Pile warp 9 is raised in row three over a knob wire which upon withdrawal forms a loop 25 of a height corresponding to the height of the knob. No pile warp is raised in row four. Pile warp I0 is raised in row five over a plain wire which upon four weft threads. nine over a plain wire and in row eleven over a knob wire. While the plain wire forms a high loop it is subsequently reduced to the height of loop 21 by action of the knob wire in row eleven when the latter is withdrawn. As pile warp 9 is buried beneath four weft threads before being I raised again over a knob wire in row fifteen the enthwire which is a plain wire.

withdrawal of the wire in this row will have no effect on the loop in row eleven. Thus, it will be seen all the series of loops formed in pile warp 9 will be low loops. The pile warp II] will form the high loops and tufts as clearly shown.

Fig. 4 illustrates an all loop pile fabric made by inserting wires i2 and 14, in alternation, during the weaving of the fabric, as shown in Fig. 5. The pile warps 9 and H] are selectively raised over the wires I2 and I4, as seen in Fig. 5, and upon withdrawal of the wires high and low loops are formed, as shown in Fig. 4. Upon withdrawal of the first wire to the right of 5, a high loop is formed in warp 10. When the second wire is withdrawn it raises warp 9 to form a loop of less height than the loop formed by withdrawal of the first wire. When the third wire is withdrawn it forms a high loop in warp 9 which is converted to a low loop upon withdrawal of the fourth wire, as the fourth wire is a knob wire and raises the loop thereon soas to pull the warp 9 and borrow yarn from the preceding loop. Thus, the withdrawal of the second, third and fourth wires will form a longitudinal series of low loops in warp 9. The withdrawal of the fifth wire forms a high loop which remains high as warp 9 is not raised over the sixth wire, which is a knob wire, but is raised over the sev- The warp ID is raised over the sixth and tenth Wires which are knob wires and when the wires are withdrawn they form low loops. By proper selection of the pile warps raised over the series of plain and knob wires weftwise rows of loops of different heights may be formed with intermediate rows of low loops no greater in height than the low loops in the rows of different height loops.

Having thus described my invention, I claim:

l. A method of weaving a pile fabric having a backing and a plurality of sets of pile warps which comprises selectively raising portions of the pile warps from the backing between adjacent weft shots. in accordance with a pattern to formalternate transverse rows of high pile loops and intervening rows of low and intermediate height loops raised in alternation between the rows of high loops, cutting the raised portions forming the high loops to form tufts, and raising the intervening rows of low pile loops to reduce the height of only those intermediate height loops of the immediate preceding row of loops raised from the same pile warps of which portions are raised to form the low loops to a height corresponding to the height of the raised low loops.

2. A method of, weaving a pile fabric having a backing and sets of pile warps which comprises selectively raising portions of the pile warps from the backing between adjacent weft shots over plain, cutting and knob pile wires in accordance with a pattern and restoring them to the backing to form transverse rows of loops, the loops on said cutting wire being higher than the loops on the plain wire and the loops on the knob wire being lower than the loops on the plain wire, successively withdrawing the pile wires whereby the loops on the cutting wire are cut to form rows of tufts and loops on the knob wire are raised in height to reduce the height of those loops formed by the plain wire that are formed from the same pile warps as the loops on the knob wire to a height corresponding to the height of the raised loops.

3. A method of weaving on a wire loom a pile fabric floor covering having a warp pile face comprising high and low pile loops which comprises inserting into the shed a plain pile wire, weaving pile warps over said pile wire to form a weftwise row of high loops, inserting into the shed a second pile wire having a low shank and high portion at its end of less height than said plain wire, selectively weaving the pile warps over the shank of said second pile wire to form a succeeding weftwise row of low loops, withdrawing said first men= ticned wire to form a row of high loops and then withdrawing said second mentioned wire to increase the height of the loops thereon while reducing the height of those loops in the first mentioned row in pile warps woven over said second mentioned wire to a height corresponding to the increased height of the second mentioned row of loops.

4. A method of weaving on a wire loom a high and low loop pile fabric having a backing and a plurality of pile warps which comprises weaving the pile warps over a relatively high wire and withdrawing the wire to form a weftwise row of high loops, weaving some of the pile warps woven over said first mentioned wire over a relatively low second wire having a raised portion on the end, and withdrawing said second wire to increase the height of the loops thereon and reduce the height of those loops of the same pile warps in the first mentioned row to a height corresponding to the increased height of the loops in said secnd row.

5. A method of weaving on a wire loom a high and low loop pile fabric having a backing and a plurality of pile warps which comprises raising the pile warps from the backing in accordance with a pattern and restoring them to the backing to form transverse rows of high and low loops arranged in alternation, increasing the height of the rows of low loops to a height less than the height of the high loops and reducing the height of only those high loops of those pile warps of which portions are raised to form low loops in the next succeeding row.

6. A method of weaving on a wire loom a pile fabric having a backing and plurality of pile warps which comprises raising the pile warps in accordance with a pattern and restoring them to the backing to form successive transverse rows of medium, high and low loops, cutting the rows of high loops to form tufts, and raising the rows of low loops to a height less than the height of the medium loops while lowering the height of those medium loops formed of the same pile warps as the low loops to a height corresponding to the increased height of the low loops.

7. A method of weaving on a wire loom a pile fabric having a backing and plurality of pile warps which comprises selectively raising the pile warps in accordance with a pattern over successive plain,'cutting and knob wires, withdrawing the plain wire to form a transverse row of loops, withdrawing the cutting wire to form a row of tufts of greater height than the row of loops and withdrawing the knob 'wire to increase the height of the lcops thereon to a height less than the height of the first mentioned row of loops while reducing the height of those loops in said first mentioned row formed of the same pile warps as the loops of the second row to a height corresponding to the increased height of the second row of loops. 4

8. A method of weaving a pile fabric on a wire 7 loom which comprises inserting a plurality of non-cutting, cutting and knob wires successively in sheds of selected warps with a cutting wire intermediate anon-cutting and knob wire, said knob wire having a shank and raised portion of less height than said non-cutting wire and said non-cutting wire being of less height than said cutting wire, weaving the pile warps over said wires to form weftwise rows of loops of intermediate, high and low height, and successively withdrawing" said wires to cut the rows of high loops and raise the rows of low loops to reduce the height of those loops of intermediate height of the immediate preceding row of loops formed from the same pile warps to a height corresponding to the height of the raised low loops.

FRANCIS P. GROAT.

REFERENCES .CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date ,09 Shuttleworth June 2'7, 1939 2,270,103 Baynton Jan. 13, 1942 77,248 Harding July 26, 1949 FOREIGN PATENTS Number Country Date 55,087 Netherlands Aug. 16, 1943 273,409 Great Britain July 6, 1927 

